Industrial Refractory Technology

Refractories are a critical part of the operation of most high temperature industrial processes and also play an essential role in many other industries. They are frequently a major cost item both in general maintenance and also the unscheduled downtime of production units arising from premature refractory failure.

The depth of the subject is demonstrated by the three-year degree courses in refractory technology, which are offered by universities throughout the world. However the majority of refractory purchasers have had little, if any, formal training in refractory technology. Numerous books and technical papers are available, but none have been written specifically for refractory users.

Refractory technology is changing so rapidly and the price of refractory materials is continuing to escalate so rapidly, that all users must conduct regular value audits on their refractory purchases.

Course Objectives

Upon successful completion of this course, the delegates will be able to:

• Identify the function and application of refractories
• Enumerate the characteristics and properties of refractories
• Classify types of refractories
• Determine the potential benefits of refractories, forms and shapes of refractories
• Recognize the typical refractories used in industrial use, selection aspects of right refractory material, potential heat losses and conservation of energy
• Explain the refractory use in metallurgical furnaces, kilns and miscellaneous equipment

Who Should Attend?

The course is a necessity to people who have a responsibility for refractory purchases, installations and who are involved in a production function. The latter will find the programme of great value in understanding the relationship between refractories and process operations.

• Maintenance Engineers
• Buyers
• Metallurgists
• Management
• Refractory Supervisors
• Refractory Foremen

This course is designed to provide comprehensive coverage and training in refractory technology and its application to a variety of industries.

Course Outline

Day 1
Refractory Materials, Compositions and Forms

• Refractory Oxides and Non-oxides
• Industrial Refractory Compositions
• Refractory Brick and Shapes
• Monolithic Refractories- Castables
• Monolithic Refractories- Plastics
• Fused Cast Refractories
• Insulating Refractories- IFB and Castables
• Refractory Ceramic Fiber

Day 2
Refractory Engineering and Installation Technology

• Thermal Criteria and Calculations
• Structural Criteria and Testing
• Chemical Criteria and Testing
• A Brief Review of Refractory Manufacturing

Day 3
Refractory Engineering and Installation Technology (cont’d)

• Installation of Refractory Brick and Shapes
• Installation of Castables
• Installation of Plastics
• Installation of Refractory Ceramic Fiber

Day 4
Refractory Applications in Industry

• Refractories for the Ferrous Industries
• Refractories for the Non-ferrous Industries
• Refractories for the Metals Heat Treating and Forging Industries
• Refractories for Refining and Petrochemical Industries
• Refractories for the Ceramic Industry

Day 5
Refractory Applications in Industry (cont’d)

• Refractories for the Glass Industry
• Refractories for Combustors, Incinerators, and Gasifiers
• Refractory Maintenance and Repair
•  Refractory Economics

Course Methodology

A variety of methodologies will be used during the course that includes:

• (30%) Based on Case Studies
• (30%) Techniques
• (30%) Role Play
• (10%) Concepts
• Pre-test and Post-test
• Variety of Learning Methods
• Lectures
• Case Studies and Self Questionaires
• Group Work
• Discussion
• Presentation

Course Fees

This rate includes participant’s manual, Hand-Outs, buffet lunch, coffee/tea on arrival, morning & afternoon of each day.

Course Timings

Daily Course Timings
08:00 - 08:20 Morning Coffee / Tea
08:20 - 10:00 First Session
10:00 - 10:20 Coffee / Tea / Snacks
10:20 - 12:20 Second Session
12:20 - 13:30 Lunch Break & Prayer Break
13:30 - 15:00 Last Session